Range Extending Charging System for an Electric Vehicle

ABSTRACT

In an electric vehicle having a primary battery powered source of energy with a primary electric motor driven and connected to one or more ground engagement wheels of the electric vehicle, has a device utilizing a sprocket and chain for collecting energy from the inner rim edge of the rear wheel of the electric vehicle. This sprocket mechanism device collects this energy then transfers that energy to a plurality of alternators on mounted framework such as in the trunk compartment by way of a chain. The alternators with their sitting pilot voltages, then transfer it by electrically conductive cables to the battery.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application is a Continuation of U.S. patent application Ser. No.15/416,849, filed Jan. 26, 2017 and currently pending, which is aContinuation-in-Part (CIP) of U.S. patent application Ser. No.14/999,673, filed May 10, 2016 and now U.S. Pat. No. 9,809,117 and isalso a Continuation-in-Part (CIP) of U.S. Utility patent applicationSer. No. 14/544,371, filed Dec. 30, 2014 and now U.S. Pat. No.9,744,864, which is, in turn, a Continuation-in-Part (CIP) of U.S.Utility patent application Ser. No. 13/317,528, filed Oct. 20, 2011 andnow U.S. Pat. No. 9,487,094. The entire disclosure of all the abovedocuments is herein incorporated by reference.

BACKGROUND 1. Field of the Invention

The present invention relates to an auxiliary power transfer device foran electric vehicle and more particularly to an auxiliary mountedsprocket source device powered by one or more wheels of an electricvehicle.

2. Description of the Related Art

Electric and hybrid electric drive vehicles powered by batteries arewell known and the electric vehicle whose drive systems are poweredsolely by battery sources are well known. Combining the multiple sourcesof energy to drive an electric vehicle has heretofore been deemedpractical.

SUMMARY

In an electric vehicle having a primary battery powered source of energywith a primary electric motor driven and connected to one or more groundengagement wheels of the electric vehicle, there is provided a deviceutilizing a sprocket and chain for collecting energy from the inner rimedge of the rear wheel of the electric vehicle. This sprocket mechanismdevice collects energy from the rotation of the rear wheel and thentransfers that energy to at least one, and generally a plurality of,alternators mounted on a framework such as in the trunk compartment byway of a chain. The alternators with their sitting pilot voltages, thentransfer it by electrically conductive cables to the primary battery ofthe electric or hybrid electric vehicle.

In an embodiment, there is provided an electric vehicle comprising aprimary electric motor powered by a primary battery bank source withelectrical energy. The primary motor being driven and connected to oneor more plurality of ground engagement wheels mounted on the electricvehicle; an auxiliary device driven and connected to one or more of theground engagement wheels; a sprocket energy collecting device mounted onthe electric vehicle for connecting to the wheels rotating energy; thesprocket energy collecting device included as an energy supply mechanismrouting energy collected from the rear wheel inner rim edge.

The energy supply device, in an embodiment, comprises a battery banksource and an electrically conductive cable connected to the primarymotor collecting device and delivering energy to one or more of theground engagement wheels.

The energy supply device further comprises connections between the twoalternator devices and receives energy from the wheel driven sprocketsending an electrically conductive cable to the battery bank source.

The primary battery bank source and the primary electric vehicle motordevices may alternately be driven and or connected electrically to acommon ground engagement wheel.

The primary electric vehicle motor device typically includes an energyregenerator connected to the battery bank source while the energyregenerator is being driven and connected to the wheel which is drivenand connected to a sprocket mechanism device mounted on the inner rimedge of the rear wheel and operating to regenerate energy for storageand usage in the battery bank source in response to the rotation of theconnected and driven wheel. A modular gear box on the other handconsisting of several hard plastic and or metal gears is known as beingcapable of replacing the sprocket mechanism devices for space andstrength are well known.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates an embodiment of a range extending charging systemmounted in an exemplary vehicle.

FIG. 2 illustrates an embodiment of a sway bar stabilizer mounted on thesteel support frame to ensure the lateral balance of the steel supportstructure by placing the ninety-degree sway bar in a recessed holefeaturing a metal keyway apparatus on the trunk floor of the vehiclethat allows the sway bar to move freely up and down with the motions ofthe entire supporting structure.

FIG. 3 illustrates another embodiment of a range extending chargingsystem mounting the system in the opposing direction to that shown inFIG. 1.

DESCRIPTION OF PREFERRED EMBODIMENT(S)

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the figures herein,could be arranged and designed in a wide variety of differentconfigurations, thus, the following more detailed description of theembodiments of the system and method of the present invention andrepresented in FIGS. 1 through 3, are not intended to limit the scope ofthe invention, as claimed, but are merely representative of thepresently preferred embodiment of the invention.

Further, the present systems and methods may be used on virtually anyelectric or hybrid electric vehicle which utilizes stored electricity asits primary source of energy. Generally, it is presumed herein that thestored electricity is stored in traditional chemical batteries, but thatis by no means required and other electric storage systems may be usedin alternative embodiments. Further, while FIGS. 1 and 3 depict thesystem positioned in an exemplary vehicle in the form of a traditionalsedan, it should be recognized that the system can be used on any formof electric or electric hybrid vehicle including those of different bodystyles (for example, hatchbacks, station wagons, or coupes), non-carwheeled vehicles (for example, trucks, sport utility vehicles,motorcycles, motorized carts, ATVs, or recreational vehicles (RVs)), andon tracked vehicles or other vehicles which utilize a drive wheel andaxle, but do not have wheels which engage the road surface (for example,bulldozers or tanks).

The presently preferred embodiments of the invention will be bestunderstood by reference to the drawings wherein like parts aredesignated by like numerals throughout the features of this structure.The structure (10) generally comprises at least one and generally aplurality of alternators (20) and (22) (usually a pair), sprockets (38),(32), (30), (24), and (26), chains (44) and (28), connectors, a sway barstabilizer (48), and a shock absorber (46) arranged on a mounting frame(18) so as to allow transfer rotational motion of the rear wheel (62) orrear axle (40) of a vehicle (12) to the alternators (20) and (22) wherethe rotational motion may be converted into electricity. Generally, therear wheel is preferred as the mounting point as there is commonly spacein a trunk or other rear position to place the device (10). However,this positioning is by no means required and the system mayalternatively be mounted to other wheels or axles depending on thedesign of the related vehicle. The mounting frame (18) is generally asteel frame (18) with all equipment mounted thereon being generallyeither welded, anchored by bolts, or otherwise attached thereto. Theframe (18) is then attached to the axle (40) so as to move with themotion of the axle (40) to maintain chain tension.

Generally, the system (10) will operate only when the electric or hybridelectric vehicle (12) moves forward. It works by using a sitting inputvoltage at the alternator windings coming from the battery circuits andignition selector contact switch to the alternator, then outputs to thebattery bank source provides a constant surge of regulated voltage andcurrent flow as long as the vehicle (12) is operating in a forwardmotion. The system can also be particularly useful for reclaimingadditional energy while the vehicle is braking or otherwise stopping. Inparticular, the system can reclaim electric energy from the rotation ofthe wheels (62) when the vehicle axle (40) is not being rotated by theonboard motor such as when the vehicle (12) is coasting or braking.

Turning now to the drawings, FIGS. 1 and 3 are perspective side views ofan embodiment of a charging system (10) in a vehicle (12). The exemplaryvehicle's trunk compartment (14) is illustrated to show the preferredlocation of the system (10) at the rear wheel (62). As can be seen fromFIGS. 1 and 3, the illustrated embodiments provide for two differentorientations of the system (10) either forward or rearward of the rearwheel (62).

FIGS. 1 and 3, illustrate the main primary steel structure and supportframe (18) revealing all of the attachment positions of the variousstructures. The steel frame (18) will preferably either be bolted orwelded to the rear wheel (62) assembly support structure in the vehicleto ensure that entire assembly (18) will preferably move up and down inunison at all times with the vehicle suspension system for smooth anduninterrupted operation and to maintain tension on the various chains(44) and (28). The charging system (10) preferably utilizes a sway barstabilizer (48) as illustrated in greater detail in FIG. 2 affixed tothe frame (18) for lateral balance relative the vehicle (12).

As should be apparent, the below discussion of the operation of FIG. 1also provides for the operational discussion of the embodiment of FIG. 3which is simply in a reversed position relative to the vehicle trunkcompartment (14) to that of FIG. 1 to help illustrate that thepositioning of the system (10) relative the vehicle (12) can be in avariety of fashions.

FIG. 1 illustrates the rear vehicle wheel (62) and rear vehicle axle(40) assembly equipped with the main drive sprocket (38) and the mainchain (44) to drive the charging system (10).

FIG. 1 also illustrates the lower chain adjusting assembly consisting ofone sprocket chain guide (42) and a chain adjusting flat sprocket (34)mounted on a guide sprocket arm (36). This lower chain adjustingassembly is generally used to tension and guide the main chain (44)during operation.

FIG. 1 illustrates the sprocket apparatus featuring the transfersprocket (32) acting as a two chain (44) and (28) junction. Thisprovides the main connecting points for a successful operation of theelectric vehicle range extender charging system (10).

FIG. 1 illustrates the upper chain adjusting plate assembly consistingof one idler sprocket (30) mechanism that connects to both alternatorsprockets (24) and (26) by the sprocket chain (28). As can be seen fromthe FIGS., the sprocket chain (28) is generally connected to thealternator sprockets (24) and (26) in a “V” pattern thus providing thata single chain (28) can drive both alternators (20) and (22).

FIG. 1, illustrates a first alternator (20) mounted on the steel supportframe and support structure (18) with a first alternator sprocket (24)connected to a flat idler sprocket (30) on the upper adjusting chainplate assembly in concert with second alternator (22) and secondalternator sprocket (26). First alternator (20) generally provides anelectrical output connection to the vehicle's battery connection input,and the first alternator (20) input is received from the vehicleignition selector switch battery output. A ground connection from thefirst alternator (20) may be connected to the ground point at thebattery to safely ground the first alternator (20).

FIG. 1 also illustrates a second alternator (22) mounted on the steelsupport frame (18) with the second alternator sprocket (26) connected toa flat idler sprocket (30) on the upper adjusting chain plate assemblyin concert with the first alternator (20) and first alternator sprocket(24). There is then a follow up connection to the dual secondarysprockets (30) and (32) as illustrated in FIG. 1. The second alternator(22) can also provide the electrical connection output to the vehiclebattery connection input, and the second alternator (22) input may bereceived from the vehicle ignition selector switch battery output.Again, a ground connection from the second alternator (22) may beconnected to a ground point at the battery.

As should be apparent from FIG. 1, it is generally preferred that themain drive sprocket (38) be substantially larger than the alternatorsprockets (24) and (28). This allows for the alternator sprockets (24)and (28) to rotate multiple times for each rotation of the main drivesprocket (38) and therefore have the alternator sprocket (24) and (28)rotate much faster than the main drive sprocket (38). For efficiency, itis desired that frictional losses in the chains and sprockets in thesystem be minimized.

FIG. 1, illustrates the shock absorber (46) mounted at the end of thesteel support frame (18) to assist in suppressing excessive verticalmovement with concerns about the overall length and weight of the steelframe support structure (18).

FIG. 2, illustrates the sway bar stabilizer (48) mounted on the steelsupport frame (18) to ensure the lateral balance of the steel supportstructure (18) by placing the ninety-degree sway bar bracket (52) in arecessed hole (50) which comprises a metal keyway apparatus on the trunkfloor (16) of the vehicle (12) that allows the sway bar stabilizer (48)to move freely up and down with the motions of the entire supportingstructure (18).

FIG. 2 also illustrates the attachment of the bracket (52) to the steelframe (18) through the use of a sandwiched connection structure. Thebottom metal base mating plate (60) is formed at a generallyninety-degree angle to attached to the structure (18). A top metal plate(54) is attached to the bottom metal plate (60) by a screw or bolt.Between the mating plates are a first rubber bushing (56) and a secondrubber bushing (58) which are compressed around one end of the bracket(52).

While the invention has been disclosed in connection with certainpreferred embodiments, this should not be taken as a limitation to allof the provided details. Modifications and variations of the describedembodiments may be made without departing from the spirit and scope ofthe invention, and other embodiments should be understood to beencompassed in the present disclosure as would be understood by those ofordinary skill in the art.

1. A method for charging an electric vehicle, the method comprising;providing a charging system comprising: a drive sprocket attached to anaxle of an electric vehicle; a chain interconnecting said drive sprocketto a transfer sprocket; an alternator chain connecting said transfersprocket to an alternator sprocket; and an alternator connected to saidalternator sprocket; and said alternator generating electricity uponrotation of said drive sprocket.
 2. A charging system for an electricvehicle, the system comprising; means for rotationally interconnectingan axle of an electric vehicle to a transfer, means for rotationallyinterconnecting said transfer to an alternator; wherein said alternatorgenerates electricity due to said rotational interconnections from saidaxle to said alternator.